1969 Dodge Charger Project 50 - Floor Replacement

Have you ever felt like you’re consistently working on a project, but it seems like you’re not really getting anywhere? Well, here we are again, working on Project 50. Project 50 is our ’69 Charger that is the basis where we plan build an environmentally safe hot rod. Starting in our September ’13 issue, we have been diligently rebuilding the Charger’s body with the help of AMD and their Installation Center. We’ve managed to complete a lot of the required work, but there is still a ways to go. We’re far from finished, but like we said, we can see light. Unfortunately, that light is not only at the end of the proverbial tunnel, it’s shining through the floor of the car. Over the years, the car has developed some damage and rust issues that need attention. Like we said before, we need to make it right, so we need to cut out the bad metal and replace it.

2/8Like we said, the floor wasn’t completely bad; it was just in the beginning stages of getting bad—or so we thought. After the mediablaster completed its job, we found these holes shining through. At first we thought they were rust holes, but further inspection revealed that someone had done a floor pan repair before we got our hands on the car. The light shining through was not rust, but actually light shining though between the spot welds.

This month, since we can see light that shines up through the driver’s side front floor we’ll need to address it. There are a couple of ways that you can tackle a job like this; smear a little fiberglass over the rust holes, cut up a road sign and pop-rivet it over the holes, or actually do it correctly. We’ve seen the effects of smeared fiberglass, and since taking a road sign to use for metal repair is illegal, we chose to do it correctly. So, a replacement panel from AMD will be installed -- yes, we’ll cut out the afflicted area before we put the new metal in. It’s not an overwhelming job to repair/replace the floor in this area, but there is a right and a wrong way to do it.

Costs for AMD driver-side floor (1⁄2 panel): $199.95

3/801 Step one: Mark the area to be cut away.

4/802 Once the metal that needs replaced is removed, be sure to clean the areas that will be welded with the new panel.

5/803 Likewise with the new metal, all primer and/or paint needs to be removed before welding can begin. The AMD installation Center has welders that will replace the factory-style welds, and look original.

6/804 The actual welding actually took less than an hour or so. Notice the stich welds around the perimeter. They are done by welding about an inch or so at a time, moving to another section, and repeating. When you’ve finished, all of the “stitches” will meet.

7/805 Don’t forget to weld the front edge.

8/806 Next month, we show you the new AMD replacement fenders. We’ll compare the replacement parts with some originals, and let you know how they stack up. mm